PEMBAHASAN RENCANA PCSU - SCHEDULE MANPOWER DLL.pptx

Rencana Precommissioning Commissioning & Startup Proyek Petrochemical

1. PROJECT ENGINEERING, PROCUREMENT, AND CONSTRUCTION AMMONIUM NITRATE 75,000 MTPY NITRIC ACID 60,000 MTPY PERFORMANCE TEST 20 MAY 2022

2. Approach to Approach to Commissioning Factory Acceptance Testing (FAT) Mechanical Completion Pre-Commissioning Commissioning Start-Up & Performance Test The Commissioning Phase can be split into 5 distinct activities that are usually performed in chronological order 1 2 3 4 5

3. Factory accep . Factory Acceptance Testing The intention of Factory Acceptance Testing is to maximize Mechanical Completion, Pre- Commissioning, Commissioning and Performance testing activities of Vendor Packaged equipment, offsite prior to release and shipment to site This includes running the package around a significant portion of the operating envelope using simulated media, temporary supplies and maximum control simulation where necessary in order to confirm that the package will function correctly and meet design and field conditions Vendor packages will undergo acceptance testing at the manufacturer's premises. These tests will be attended by members of the Project and Operations teams, in accordance with a FAT Program 1 2 3 QC akan mengumpulkan : MDR (Manufacture Data Report – yang meliputi hasil FAT, Prosedure SAT yang akan dilakukan , dsbnya ) Approval terhadap pengujian dan catatan perbaikan yang dimintakan Owner Pengujian setiap alat di lapangan dikenal sebagai SAT/ PreComm dapat dilakukan dengan beberapa kondisi untuk menguji kebali peralatan dengan pertimbangan konstruksi belum selesai dilakukan yakni dengan mencari workshop yang menyediakan kondisi yang sama seperti saat di FAT atau menyediakan sumber daya di lapangan Pengujian yang dilakukan hanya bersifat uji jalan atau uji tekan , sehingga baik pump, vessel, tank, dll hanya akan dilakukan pengujian dasar tersebut dengan beberapa test yang berhubungan seperti noise, vibrasi dll Untuk saat ini yang dapat dilakukan adalah membandingkan hasil FAT dengan desain , dengan syarat FAT mengikuti standard yang ada FAT should be witnessed and accepted by the discipline QC & engineers, package engineers and/or third party inspection services at the manufacturers site 4 FAT untuk scope SEDIN adalah tanggungjawab SEDIN, sehingga pelaksanaanya hanya melibatkan SEDIN dan KAN. Apakah WIKA mengirimkan Perwakilan pihak ketiga untuk melakukan FAT semua Equipment ? Sehingga Batasan tanggungjawab , hasil seperti apa – QC & Eng.

4. Factory accep . Factory Acceptance Testing Copies of the completed Factory Acceptance Test (FAT) procedures and associated acceptance certification should be made available to the Commissioning Manager complete with all deviation requests, release notes and outstanding punchlist items Manufacturers drawings, O&M Manuals and certification books, etc , should be issued in a timely manner to support site installation, commissioning and handover to operations 5 6 The vendor should provide SAT procedures that will be implemented on site and verify that the equipment/software has been assembled/loaded and tested to the requirements of the supply contract The SAT procedure will be accepted by the respective commissioning engineers prior to commencing pre-commissioning activities on site 7 8

5. Mechanical Co Mechanical Completion Physically Complete Tight Functional Tested Constructed, installed and connected as per design Everything is checked, in working order Lubricants are added to machinery Equipment is aligned Operability check have been performed Safe Clean Mechanical Completion means the System or Sub-System is: There is no loss of pressure or leakage from equipment, piping, joints, etc can operate as intended Equipment has been successfully inspected, tested and certified as required The facilities are inherently safe and all systems for the protection of personnel, environment and property are installed, operational and documented The facilities have been flushed, are clean, dry and have the necessary temporary equipment installed ready for Commissioning

6. Mechanical Co Mechanical Completion Item MC - Electrical Activity Example of earth loop tests Verification of manufacturer's equipment and certification details against Check and inspect the earth system connections design specifications including Hazardous Area and IP ratings Check for continuity of the main earth system loop and continuity of the taps of equipment. Completeness of Installation against the approved design Check earthing resistance. Insulation Resistance testing Point to point testing Check of earthing connection to equipment rightness. Protection Relay Tests and lighting system Check of adequate mechanical protection of earth wire (if required). Continuity testing and attenuation measurement Continuity test for earthing mesh branches. Earth Loop Impedance tests Earth grid and ground loop wire sizes (electric and instrument grounding system). Earth Bar resistance checks   Over potential (Hi Pot) testing   Verification of Heat Tracing Installations   Communications equipment testing   MC - Instrumentation / Control / Fire & Gas / ESD Activity Example Verification of manufacturer's equipment and certification details against design specifications including Hazardous Area and lP ratings Instrument tagging Completeness of installation against the approved design Model number and instrument classification. Calibration of instrument devices and equipment Size and connections. Attenuation, continuity testing of fibre -optic cables Material of construction. Calibration and cycling of Control Valves Instrument range and calibration. Continuity testing and attenuation measurement Valve action and air/electrical failure positions Relief Valve testing   Pressure testing of impulse pipe and tubing  

7. Mechanical Co Mechanical Completion Item MC-HVAC MC-MECHANICAL Verification of manufacturer's equipment and certification details against design specifications including Hazardous Area and IP ratings Verification of manufacturer's equipment and ancillaries against design specifications Completeness of installation against the approved design Completeness of installation against the approved design Alignment of motor and fan drives Bore scope inspections Mechanical operation of linkages and damper blades Rotational checks Confirmation of correct airflow direction in pre-heaters Equipment alignment checks   Firefighting equipment inspection   Lifting equipment checks

8. Mechanical Co Mechanical Completion Item MC - PIPING Activity Example Vessel Example Pipe Completeness of installation against the approved design Conformity with project documentation. Conformity with P and I flow diagrams. Non-destructive examination Pressure, temperature, rating. Size Flange and nozzle alignment checks Nozzles, sizes and orientation. Pipe: flanges, gaskets, fittings, valves in conformity with specified piping classes Bolt tensioning Internals: types, dimensions, metallurgy and installation. High point vents and low point drains. System flushing Instrument nozzles and types. Instrument nozzles and types. Hydro-testing Ladders, platforms, walkways: Location, size and accessibility. Pipe supports and spring hangers. Re-instatement Nameplate information/data. Flange bolting tightness: nuts, gaskets and bolts are properly installed Coating systems checks and pipe marking Grounding connections. Orifice plates in correct location and direction. Pipe support checks Vents, drains, relief valves provided as specified. Spacers and spectacles are properly installed at the open or blind position 3D laser survey results available for items requiring Dimensional Control     Chemical cleaning     Pickling     Vacuum/air drying     Installation of temporary strainers    

9. Mechanical Co Mechanical Completion Item FLUSHING OR BLOWING THE PLANT Small pieces of mill scale, weld rod stabs, weld spatter, insulation, paper, wood and other debris are sometimes unavoidably left in piping and equipment on completion of construction The P&I Diagrams are used to prepare the flushing sequence and to follow the progress of flushing. Finally, manual fine cleaning may be necessary Use compressed air for piping blow down after flushing A systematic program for flushing with water or blowing with air will eliminate most of the debris that might obstruct control valves and orifice plates restriction orifices or damage machinery The fire water circuit should be washed Special attention must be paid to certain piping systems such as lubricating oil and mechanical seal circulation systems where small orifices and openings are present. It may be necessary to dismantle the piping to clean it mechanically or by pickling. Once these systems are clean, they must be kept clean to prevent repetition of the cleaning operations. These specialized systems are the Supplier responsibility and normally are cleaned prior to shipment. If further cleaning has to be done, it shall be conducted by Supplier representative instructions and responsibility. The flushing and cleaning entails whatever work is necessary to obtain a clean unit ready for process operation. Part of this work can be accomplished after hydraulic test execution and before final reinstatement of the piping All control valves should be removed and flushed from both directions using the bypass and in-line valves, if possible. Otherwise, open and clean all control valves after flushing are completed, where will be difficult to remove them Only fresh water and compressed air should be used Instruments must be disconnected or isolated. Restriction orifice and rotameter must be taken away, if have been installed. Dirties and debris should be flushed from the unit and not into it. Circulated flushing of the piping system within the plant may be carried out, where it is possible. If water circulated flushing, using process pumps, is applied for system cleaning, special care for over load trip must be taken '90due to higher density than design condition. Provisional strainers are installed and periodically cleaned. Spraying nozzles must be installed after relevant lines have been flushed to avoid clogging. If necessary, take out the flapper of check valves (previous check of the availability of spare gaskets) For temporary flushing, use compressed non- asbestos gaskets. Insert proper gasket only for the final re-assembling of the unit. Water is supplied with temporary flexible hoses. Prior to flushing, make a manual cleaning to minimize obstruction. All blinds inserted into lines or equipment must be recorded, and drawn out after flushing. The water should be drained from every low point Final reinstatement of piping after flushing/blowing/cleaning activities shall be supervised by Commissioning Integrated Team (CIT) engineers to report the conformity with the design

10. Pre- Commiss P re-Commissioning Physically Complete Tight Functional Tested The System/Sub-System has been constructed, installed and tested under power in accordance with the design documents, Vendor documents and other applicable documents as required. Safe Clean There is no loss of pressure or leakage from equipment, piping, joints, etc.. during running Can operate and running as intended. Equipment has been successfully energized and tested. The facilities are inherently safe and all systems for the protection of personnel, environment and property are installed, operational and documented Everything is tested, in working order, lubricants are added to machinery, equipment is aligned, operability checks have been performed and the equipment is ready for Commissioning.

11. Pre- Commiss P re-Commissioning Inspection and testing activities performed to achieve System/Sub System Acceptance are: Carried out on a single discipline basis. Requires energized checks on systems Include tests by specific discipline. All tests are documented on type "B" ITR’s (Inspection test report) and the status of completion recorded within and monitored by the Completions & Certification Management System (CCMS). Pre-Commissioning consists of powered up (energized) checks and proves the correct operation of the equipment under simulation prior to the introduction of utility media

12. Pre- Commiss P re-Commissioning Item Precomm - Electrical Activity Example of Switchgear & MCC checks Energize Electrical systems Complete component and interconnection and cable terminations inspection according to manufacturer's final approved drawings. Switchgear & MCC checks and Function Checks Inspection, testing and functional check shall be according to supplier instruction. Alarm, Trip, ESD and Control Settings Pressure and Power frequency testing Voltage, polarity and phase rotation checks Make all necessary adjustment to switch gear and motor control center equipment Uncoupled / no load motor runs and performance tests Test and calibration of all switch gear relays (using primary and Secondary injection as applicable), metering, lights, indicators, space heater, and check proper coordination and setting. Breaker operation Check the phase sequence and polarity of all equipment Motor runs Functional check of all motor starters, circuit breakers' incomers, outgoing Feeders and bus ties. Load Testing and lighting system test. Perform operational tests on all motor control circuits, interlock system, indicating lights, meters and all other devices. Run tests and energized rotation tests of electrically driven motors Check circuit breakers, motor starters, relays and other equipment for loose connections (both mechanical and electrical). Verify that contacts and working parts are correctly aligned and free from dust and foreign matter. Auto / Manual operation Inspect circuit breakers with adjustable trips, checking both thermal (if any) and magnetic settings for proper protection. Also check thermal overload relay settings according to vendor documents.   Check and sequence test for alarms, interlocks, auto-transfer, ... etc.   Functional checking of switchgear and MCC from remote locations such as Control Room.   Energizing the substation for readiness of plant commissioning and start-up.

13. Pre- Commiss P re-Commissioning Item Precomm - Instrumentation / Control / Fire & Gas / ESD Activity Example Energize Control systems Level DP transmitters. Loop testing Analogue input / output tests Pressure transmitters. Digital input / output tests Temperature transmitters. Frequency tests Transducers. Auto / Manual switching Petitioners. Control System configuration After completion of this work QA/QC stickers should be fixed on the instruments, then, the check form shall be signed by all concerned parties. System integrity testing (i.e. Communications between Control Systems)   Control panel functional testing   Precomm-HVAC Precomm-MECHANICAL/PIPING Precomm-COMMON Damper and actuator Operation Installation of temporary strainers Package equipment function and energized tests Removal of internal preservation Temperature device operation Load testing of Lifting equipment Removal of temporary bracing Ductwork Leak Tests Pre-Commissioning of Lubrication, Cooling, Fuel, Seal Gas and Hydraulic systems, including flushing, circulation, draining and re-filling as required by the specification Activation of all piping spring hangers Air Conditioning equipment operation Coupling of rotating equipment Testing of Lifting Equipment for 3rd party inspection Charging of systems Operation of Fans and Air Handling Units Vibration and Noise testing Loading of Selected Chemicals Airflow and balance testing Mechanical seal integrity checks Discharge / retention testing   Final inspection of vessels Verification of media quality   Critical Valve Testing     Relief Valve re-setting  

14. Commissioning Commissioning Commissioning means : Commissioning items : The plant systems and sub-systems operate together in an integrated manner in accordance with the design objective and meet the performance criteria regarding operational requirements and occupational safety requirements Gross Air Leak Testing Punch Listing The documentation is adequate for full facility operation, describing accurately the plant and procedures. Nitrogen or Helium Leak Testing Test Runs Staff skills are appropriate to operate the plant in accordance with competency requirements, occupational health and safety requirements. Installation of temporary systems if required for commissioning use and start up Integrated Runs The new facilities perform as designed Identification and charging of first fills. Dynamic Instrument testing The new facilities interface appropriately with the existing facilities Vendor control Preservation and Maintenance All Commissioning activities are performed using 'SAFE' fluids with the exception of Compressor Surge Mapping Cause and effect logic tests Control logic checks Safety Systems testing DCS functional testing PLC Functional tests ESD Functional testing Surveys Commissioning procedures will be produced and contain detailed step by step instructions that will be followed when starting for the first time and placing equipment and systems into operation. Once the procedure has been successfully completed the system is deemed to be fully compliant with the design Fire & Gas Functional testing Operator Training The commissioning activities will prove the new facilities interface with all other associated systems and bring the entire plant to a state of readiness for normal operation and handover Optimization of room pressure and temperature  

15. Start-Up Start-Up Start-up means : Start-up items : The initial introduction of "LIVE fluids" into the completed systems and ramp up of production to a steady state. Initial introduction of Fluida , stabilization and short running Pre-requisites for Start-Up are; Check pipe supports, hangers, guides and anchors under running condition The state of a system / sub-system where by all Mechanical Completion Certification has been issued; Pre-Commissioning and Commissioning activities are complete such as inerting, drying, function testing of instrument, equipment and safety systems, and integrity leak testing have been completed Check noise levels No open punch list items remain that will be detrimental to the personnel safety or safe operation of the system Mini shutdown for the removal of temporary strainers and blanks Start-up Authorization has been received where required from Operations. Restart   Progressive increase of throughput   Phased handover to Operations

16. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up 11 JANUARY The schedule for testing will be according to the construction and installation program. An extensive inspection and test program is planned for the new facilities and auxiliary systems. During the pre-commissioning test phase, testing will be performed as system MC hand-over from construction allows. Key systems will be sequenced for completion and testing early enough to provide necessary auxiliary services for testing and operation of other systems Examples of such key plant systems are the electrical system and compressed air system The sequencing of tests shall be such so that safety of the facility is never dependent on the performance of untested systems, sub-systems and components.

17. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

18. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up Vendor Site Support The Work The relevant Discipline Commissioning Engineer will be responsible for the vendor carrying out the work within the time forecast. The Construction / Commissioning Manager will be responsible for the provision of any services or support required by the vendor to carry out the work in order to ensure there is no delay. Forecast and Budget The need for vendor assistance shall be pre-planned and be facilitated by having in place vendor call-off contracts against those vendors whose assistance is anticipated, or contingency against those vendors considered desirable. Vendor Site Visit Close-Out Upon completion of the work to the satisfaction of the relevant Commissioning Engineer and the Construction / Commissioning Manager the Vendor Representative shall complete all final time sheets and reports and obtain the necessary approval signatures. Preservation and Maintenance The Preservation and Maintenance of installed, inspected and tested equipment will remain the responsibility of the project until such a time as the new facilities are handed over and accepted by Operations. Equipment Preservation and Maintenance activities will be carried out by the Commissioning Team and documented using specific ITR's within the Completions Management system. Preservation and Maintenance reports will form an integral part of the system hand over dossier.

19. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

20. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

21. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

22. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

23. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

24. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up

25. Process Plant Process Plant Pre-commissioning, Commissioning and Start-Up